System for measurement of molten sulfur level in receptacles

ABSTRACT

A portable temperature sensing probe having a plurality of thermocouples is inserted into a tank mounted on a truck or other receptacle at the time of loading a hot liquid, e.g., molten sulfur. The probe and at least a portion of the associated wiring or leads are attached to the loading pipe and/or discharge nozzle, and the probe is inserted into the interior of the tank before the molten sulfur is discharged. The signals from the plurality of thermocouples are amplified and the corresponding temperature information is transmitted to a display and control device. Due to the significant differential between the temperature of the rising molten sulfur and the vapors in the tank overhead space, the signals generated indicate which of the thermocouple are in contact with molten sulfur or the vapor zone. The generated signals adjust the shut-off valve that controls the flow of molten sulfur into the tank.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of U.S. application Ser. No.10/551,736, filed on Feb. 28, 2007, which corresponds toPCT/US2004/10177, filed on Mar. 30, 2004, which claims priority on U.S.application No. 60/459,037, filed on Mar. 31, 2003, all of which areincorporated herein by reference.

FIELD OF THE INVENTION

The invention relates to the measurement and control of the flow ofmolten sulfur that is being added to a container or receptacle, forexample, to a steam jacketed tank truck for transportation or to asulfur pit for storage.

BACKGROUND OF THE INVENTION

Molten sulfur is produced as a natural raw material and as a by-productin chemical processes, such as the “sweetening” of crude oil. In orderto transport the sulfur for eventual disposition, it is commonlymaintained in a molten state so that it can be pumped and deliveredthrough pipelines as a viscous liquid. Steam jacketed tank trucks arecommonly utilized to transport the molten sulfur from an industrialproduction area to a storage location where it is typically pumped fromthe truck into a sulfur pit or storage tank.

It is important that the sulfur remains molten throughout the truck'stank and pumping system, since any solidification can seriously damagethe pump.

The transporting tank trucks are equipped with a covered hatch intowhich a discharge or loading nozzle from a connecting pipe line isinserted. A shut-off valve is provided for either manual or electroniccontrol of the flow-rate through the pipe line and nozzle into theinterior of the tank.

One early method of determining when the molten stream should be shutoff was to make a direct visual observation of the rising level of thesulfur in the tank. This method was inherently dangerous, since themolten sulfur has a tendency to splash and could cause severe burns onunprotected flesh. Furthermore, the fumes exiting the hatch as theliquid displaced the gases in the overhead are unpleasant at best, andcould contain other vaporized compounds that are hazardous to health ifinhaled.

Present methods of determining the temperature and the level of themolten sulfur as it rises in the truck's tank are not satisfactory. Theuse of instruments such as a capacitance and vibration probes, radarmeter probes and ultra-sonic probes have proven to be unsatisfactory. Aswill be apparent to one of ordinary skill in the art, the result ofcooling of the molten sulfur is its solidification on measuringinstruments. Although viscous, the molten sulfur has a tendency tosplash and the drops formed can rapidly cool to the solidificationtemperature. The encrusted sulfur has been found to interfere with theaccurate performance of various types of liquid measurementinstrumentation. The failure to obtain an accurate temperature readingcan result in damage to the unloading pumps due to solidified sulfur.

One method for safely controlling the volume of molten sulfur loadedinto a tank truck is to provide a scale at the loading station. Thetruck is weighed as it arrives empty at the loading station and thevolumetric capacity of the truck is converted to the equivalent weightof molten sulfur to be loaded. As the weight of the truck approaches thepredetermined capacity, the valve can be closed when the desired volumehas been added. While this solution is satisfactory, the expenses ofinstallation and subsequent maintenance of one or more scales at thetank truck loading stations is substantial.

It is therefore an object of the present invention to provide anapparatus and method for measuring the level of molten sulfur as thesulfur is discharged into a receptacle, such as a tank truck or storagetank or pit, that is relatively inexpensive and that can be used toreliably provide information on the level of molten sulfur or othersimilar hot molten materials. Another object of the invention is toprovide a durable, damage-resistance measuring and signal-generatingdevice, that can be completely automated for generating a control signalfor actuating the molten sulfur flow shut-off valve.

SUMMARY OF THE INVENTION

The above objects and other advantages are achieved by the method andapparatus of the invention in which a portable probe having a pluralityof thermocouples is inserted into the tank truck or other receptacle atthe time of loading. In one preferred embodiment, the probe and at leasta portion of its associated wiring or leads are attached to the loadingpipe and/or discharge nozzle. In this embodiment, the temperaturesensing probe is inserted into the interior of the tank before themolten sulfur is discharged.

The thermocouples or other temperature sensing and signal generatingdevices are secured in a vertical array, preferably on anon-electrically conductive elongated member. In a further preferredembodiment, the elongated member is surrounded, at least in part, by aprotective sheath. If the sheath is metal or other thermally and/orelectrically conductive material, the temperature sensing devices shouldbe appropriately insulated or isolated from the sheath.

In a particularly preferred embodiment, the signals from the pluralityof thermocouples are amplified and the corresponding temperatureinformation is transmitted to a display device. The display device caninclude a direct display of the temperature at one or more of thethermocouple positions within the molten sulfur and in the overheadspace in the interior of the tank.

In another embodiment, the temperature signal can be converted toprovide a display of the volume and/or level of molten sulfur in thetank. As a result of the significant temperature differential betweenthe rising molten sulfur and that of the vapors in the space definingthe tank overhead, the signals generated will clearly indicate whetherany particular thermocouple or group of thermocouples is in moltensulfur or in the vapor zone.

In a further preferred embodiment, the signals generated by thethermocouple array are further processed to control the shut-off valvethat controls the flow of molten-sulfur into the tank. In thisembodiment, one or more thermocouples at the upper end of the probeadjacent the loading hatch opening will generate signals that areconverted to gradually reduce or quickly close the flow control valve.The particular programming of this function can be based on the geometryof the tank that is being loaded. For example, a circular tank willrequire smaller volume to raise the level a given distance as the tankapproaches its full capacity. On the other hand, a tank having a morerectilinear cross-section with generally vertical sides can exhibit amore or less steady rise in level for a given volumetric flow rate.Similar considerations apply to sulfur pits or stationary tanks thathave vertical sides and either a circular or rectangular cross-section.

As will be understood by those of ordinary skill in the art, amicroprocessor can be programmed with information relating to the one ormore types of tanks mounted on trucks that are being filled at aparticular station in which the probe of the invention is in use. Forexample, if there are three different tank designs in use on vehiclesused to transport molten sulfur, each can be given an arbitrarydesignation, such as type A, B and C. When the truck arrives at thestation for filling, the operator or truck driver that is responsiblefor inserting the probe and discharge nozzle into the truck's fillinghatch identifies the type of truck to be filled, e.g., by using a keypad, lever or other switch that is connected to the microprocessorcontrol circuit.

An optional visual display indicating the volume or capacity of theparticular type of tank can also be provided for use by the operator. Anaudible signal can also be provided to indicate when the tank reaches apredetermined condition, e.g., 90% full in order to alert the operator.

A further optional feature comprehended by the invention is to provide adifferent audible signal and/or emergency shut-off switch connected tothe control valve in the event of a failure in

-   -   the electronic measuring and/or mechanical control system.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are described hereinbelow withreference to the drawings wherein:

FIG. 1 is a schematic drawing of a loading system with a temperaturesensing probe constructed in accordance with the present invention;

FIG. 2 is a side elevation view of the probe of FIG. 1;

FIG. 3 is a cross-sectional view of the probe of FIG. 2, taken alongline 3-3;

FIG. 4 is an exemplary embodiment of the probe of FIG. 3;

FIG. 5 is another exemplary embodiment of the probe of FIG. 3;

FIG. 6 is a side elevation view, in cross-section, of a junction of theprobe of FIG. 2 using a thermocouple;

FIG. 7 is a view similar to FIG. 6 using a transistor;

FIG. 8 is a view similar to of FIG. 6 using a resistance temperaturedetector;

FIG. 9 is a schematic drawing of a representative processor for use inthe loading system of FIG. 1;

FIG. 10 is a schematic view of an alternative embodiment of a processorfor use in the loading system of FIG. 1; and

FIG. 11 is a flowchart illustrating one preferred mode for operating theloading system of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1-11, a portable temperature sensing probe 10 is usedin a loading system 12 for loading a heated liquid material 14 into acontainer 16. The probe 10 includes a plurality of temperature sensingjunctions 18 which directly contact the heated liquid material 14 whenthe probe 10 is inserted into the container 16, such as a tank mountedon a truck, a storage pit, or other stationary receptacle, at the timeof loading the heated liquid material. In a preferred embodiment, thecontainer 16 is a steam-jacketed tank having an inner compartment 20 forretaining the heated liquid material 14, for example, in a molten state.

In the exemplary embodiments described herein, the heated liquidmaterial 14 is molten sulfur. In one preferred embodiment, the probe 10and at least a portion of the wiring or conductive leads from thejunctions 18 are attached to the loading pipe 22 and/or dischargenozzle, for example, by an optional coupling member 24 or otherfastening devices. In this embodiment, the temperature sensing probe 10is inserted through the container opening 26 into the interior of thecontainer 16 simultaneous with the loading pipe 22 before the moltensulfur 14 is discharged and/or before additional molten sulfur is pumpedinto a partially filled container 16.

In a particularly preferred embodiment, the junctions 18 includemodified thermocouples, and the signals from the plurality ofthermocouples are amplified, with corresponding temperature informationbeing transmitted as temperature signals to a processor 28 connected tothe probe 10 for processing and output to an output stage 30, which caninclude a display device. The display device can include a directdisplay of the temperature at one or more of the thermocouple positionsof the junctions 18 within the molten sulfur 14 and the overhead region26 or vapor zone in the interior of the container 16 above the topsurface 34 of the molten sulfur 14. In another embodiment, thetemperature signals can also be converted to a display of the volumeand/or level 34 of molten sulfur 14 in the container 16, such as anumerical or graphic display showing the volume in metric tons, as apercentage of the container capacity, or other informational displaymethods.

As a result of the significant temperature differential between therising molten sulfur 14 and the vapors 36 overhead in the vapor zone 32of the container 16, the signals generated will clearly indicate whetherany particular thermocouple or group of thermocouples of the pluralityof junctions 18 is in molten sulfur 14 or in the vapor zone 32.

In a further preferred embodiment, the signals generated by thethermocouple array of the plurality of junctions 18 are furtherprocessed by the processor 28 to control a shut-off valve 38 thatcontrols the flow of molten sulfur 14 into the tank 16 from a source 40of the molten sulfur 14. The processor 28 is connected to the valve 38by a transmission connection 42, such as a wire, for transmitting acontrol signal from the processor 28 to a controller of the shut-offvalve 38, for example, after a tank on a truck has been filled. Thevalve 38 can then be reset to start the loading of a new tank.

By controlling the flow of molten sulfur 14 or other liquid materials inwhich solidification is a concern, the invention using the probe 10 asdescribed herein is suitable for use with other known methods andmechanisms for measuring and/or controlling the liquid level in thecontainer 16.

In this embodiment, one or more thermocouples at the upper end of theprobe 10 adjacent the loading hatch opening 26 will generate signalsused to provide a control signal to gradually reduce or quickly closethe flow control valve 38. The particular programming of this functioncan depend upon the geometry of the tank 16 that is being loaded. Forexample, a circular tank will require smaller volume to raise the levela given distance as the tank approaches its full capacity. On the otherhand, a tank having more nearly vertical side walls and constantvertical cross-section will exhibit a more or less steady rise in levelfor a given volumetric flow rate.

The spacing of the temperature sensing and signal generating devices 18can be determined by the tank shape and geometry to provide more data asthe level of molten liquid reaches the desired position in thecontainer. Two or more devices 18 can be placed in close proximity inorder to provide fail-safe redundancy for each vertical location on theprobe.

FIG. 2 is a side elevational view of the probe 10 of the invention, inwhich the probe 10 includes an elongated body 44 extending from aterminal head 46. A plurality of apertures 48 are provided in the outersurface of the body 44, in which a corresponding plurality of junctions18, labeled J₁, J₂, . . . J_(N), are generally equidistantly positionedto contact molten sulfur when the body 44 of the probe 10 is insertedinto the molten sulfur 14. The plurality of apertures 48 can bepositioned in a row along one side of the body 44. Two or more junctions18 can be located on the periphery at the same vertical location.

Lower end 50 of the body 44 can optionally be tapered to facilitateinsertion of the probe 10 into the molten sulfur 14. The terminal head46 is dimensioned to house a plurality of electrical signal conveyingmembers, such as wires, extending internally from the junctions 18, asshown in FIG. 3, and out through a port 54 to be connected to theprocessor 28 to transmit signals from the junctions 18 to the processor28. The conductors can be affixed to terminals in mating sockets tofacilitate routine maintenance and repair of the components comprisingthe assembly.

In addition, the terminal head 46 can be dimensioned to include an edge56 to allow the terminal head 46 to be grasped for manual manipulationfor insertion and removal from the container 16, and optionally to reston the edge of the opening 26 of the container 16 to prevent the probe10 from falling completely into the molten sulfur 14 in the container16. In addition, the coupling member 24 can be fastened to the, terminalhead 46 and/or can include a loop through which the probe 10 is passedwith the edge 56 resting on the loop to prevent the probe 10 fromfalling entirely into the container 16.

As shown in the cross-sectional view of FIG. 3, the junctions 18 aremounted into the side of a rod 58 composed of insulating material, forprotecting the internally disposed electrical signal conveying members,such as wires, from the extreme temperatures of the molten sulfur 14,and for preventing electrical contact between electrically isolatedjunctions 18.

The rod 58 can optionally be surrounded by a protective sheath 60forming the outer surface of the body 44 and having the plurality ofsmall apertures 48 through which the junctions 18 are directly exposedto the molten sulfur 14 for the best heat conduction for accuratetemperature sensing.

In a preferred embodiment, the sheath 60 is composed of stainless steelof relatively low thickness, and with a relatively small diameter,depending on the number of measuring junctions 18. By using stainlesssteel, the sheath 60 gives more support and protection to the probe 10and the internal rod 58 when moving the probe 10 with the loading arm 22during insertion into the container 16. Accordingly, the sheath 60prevents damage to the junctions 18 during manipulation and use of theprobe 10. The junctions should not be in contact with the heatconductive sheath.

The plurality of junctions 18 are electrically connected by theplurality of electrical signal conveying members, such as wires 62, to adata bus 64 for conveying electrical signals and optionally forproviding electrical power to the junctions 18 from an external powersource, for example, a voltage source provided by the processor 28. Thedata bus 64 also transmits electrical signals, such as voltages orcurrents, as the temperature sensing signals generated by the junctions18 through the port 54 to the processor 28.

Referring now to FIG. 4 there is illustrated a first exemplaryembodiment of the probe 10 of FIG. 3, with the data bus 64 includingnumerous individual wires 66 extending from the junctions 18, such thateach individual junction 18 has at least two wires directly connectingthe respective junction 18 to the processor 28 to transmit thetemperature sensing signal to the processor 28 for processing.Optionally, an amplifier 68 can be positioned between an individualjunction 18 and the processor 28, for example, as shown in FIG. 4 forjunction J_(N), for amplifying the respective temperature sensing signalfor transmission to the processor 28. Since the temperature sensingsignals from the junctions 18 can be voltages which are typically in themillivolt range, increasing the voltage output from the junctions 18using the amplifiers 68 reduces errors and uncertainties in thetemperature measurements. The use of amplifiers 68 also facilitatestransmission of the temperature sensing signals to a processor 28 usinganalog components, as described below with reference to FIG. 10.

Alternatively, the processor 28 can include the amplifier 68 or anamplifier stage for amplifying some or all of the temperature sensingsignals from the junctions 18. The number of junctions 18 and theirrespective wires in the data bus 64 can determine the length andthickness of the probe 10.

Referring to FIG. 5, a second exemplary embodiment of the probe 10, thedata bus 64 includes wires 70, 72, 74. The first wire 70 connects theprocessor 28 with the lowermost junction 76, labeled J₁ and can providean operating voltage. The second wire 72 connects the processor 28 tothe uppermost junction 78, labeled J_(N). The intermediate wires 74connect successive junctions 18 in a series arrangement, such that thejunctions 18 generate the temperature sensing signals to readily measuretemperature differences along the row of junctions 18 extending alongthe length of the body 44 of the probe 10 while reducing the number ofwires to the data bus 66.

FIG. 6 is a cross-sectional view of one of the plurality of junctions 18of the probe 10, in which the junction 18 is embodied as a thermocouple80 positioned in the aperture 48 in the sheath 60. The thermocouple 80includes a pair of wires 82, 84 connected to respective contacts 86, 88which in turn extend through the insulating material of the rod 58 to beconnected to the data bus 64 shown in FIG. 3. The wires 82, 84 arecomposed of dissimilar metals which produce an open circuitelectromotive force (EMF) which is related to the temperature differencebetween the junction 18 and a reference junction. The EMF is a voltagewhich is the temperature sensing signal sent to the processor 28.

The reference junction can be the uppermost junction 78, labeled J_(N),or alternatively can be the plurality of junctions 18 immersed in an icebath prior to insertion of the probe 10 into the molten sulfur 14.Thermocouples 80 have a polarity, such that one wire 82 can be apositive wire and the other wire 84 is then the negative wire, whichdetermines the flow of the EMF. In a preferred embodiment, thethermocouple 80 is a type K thermocouple, with positive wire 82 beingcomposed of “CHROMEL” brand alloy, commercially available from HOSKINSMANUFACTURING COMPANY CORPORATION, with chemical composition Ni 90% andCr 10%; and the negative wire 84 being composed of “ALUMEL” brand alloy,commercially available from HOSKINS MANUFACTURING COMPANY CORPORATION,with chemical composition Ni 94%, Mn 3%, Al2%, and Si1%. Suchthermocouples are useful for molten liquids with temperatures rangingfrom −300° F. to 2300° F., and the temperature-to-voltagecharacteristics of these thermocouples are generally substantiallylinear for this combination of metals forming the thermocouples, and areparticularly suitable for use with molten sulfur 14.

In an alternative embodiment of the junction 18, FIG. 7 is across-sectional view of a junction 18 of the probe 10 using a transistor90 having a plurality of leads 92 extending to the data bus 64. In thisembodiment, the properties of transistors having voltage characteristicsdependent on the temperature are used to measure differences in thetemperature compared to a reference transistor. Since transistors can beinstalled with generally small dimensions and/or a generally largenumber of transistors can be installed over a given length of the probe10, this embodiment using transistors can be manufactured to be of asmall size so that the probe 10 has a smaller diameter and can bemanufactured with a very large number of junctions 18 to provide agreater resolution in sensing temperature differences over the length ofthe probe 10.

In a further alternative embodiment of the junction 18, FIG. 8 is across-sectional view of a junction 18 using a resistance temperaturedetector (RTD) 94, which utilizes the temperature dependency ofresistance, for example, a resistor 96, to detect the temperature of themolten sulfur 14 at the respective junction 18. As the resistance acrossthe resistor 96 changes, the voltage and/or the current through thewires 98 changes, indicating the temperature. The RTD 94 can be a thinfilm platinum device of the type commercially available from OMEGAENGINEERING, and can have a temperature range from −320° F. to 1,000° F.

As will be understood by those of ordinary skill in the art, theprocessor 28 can include components shown in FIG. 9 for receivingsignals from the junctions 18 corresponding to temperatures of themolten sulfur 14, and digitally analyzing the temperatures to digitallycontrol the valve 38. The processor 28 acts as a control circuit and caninclude a microprocessor 100 and a memory 102. Optionally, the receivingsignals from the junction inputs via the port 54 are digitized using ananalog-to-digital (A/D) converter 104 using A/D conversion methods knownin the art.

The microprocessor 100 performs various calculations on the digitizedsignals from the A/D converter 104 using hardware and/or software whichcan be programmed with information stored in the memory 102 relating tothe one or more types of trucks that are being filled at a particularstation in which the probe 10 of the invention is in use. For example,if there are three different tank designs in use on vehicles used totransport molten sulfur, each can be given an arbitrary designation suchas type A, B or C. When the truck arrives at the station for filling,the operator or truck driver that is responsible for inserting the probe10 and discharge nozzle 22 into the truck's filling hatch 26 identifiesthe type of truck to be filled, e.g., by using the input device 106,such as a key pad, a lever, a switch or other device that is connectedto the microprocessor-based control circuit of the processor 28.

In one embodiment, the microprocessor 100 includes a display datacalculator 108, a temperature mismatch function calculator 110, a logiccircuit 112, and a valve control circuit 114, implemented in hardwareand/or software. The display data calculator 108 determines the varioustemperatures and related data from the temperatures detected by theprobe 10 and stored in the memory 102. The related data can include thevolume of the molten sulfur 14 in the container 16, the level of moltensulfur 14 in the container 16, the current or remaining maximum volumeor capacity of the particular type of container 16, etc.

Such display data are output to the output stage 30 for display by adisplay device 116 for use by the operator, for example, to manuallyturn off the valve 38. Alternatively or in conjunction with visualindicators, an audible signal can also be provided using an audio deviceknown in the art and included in the output stage 30 to indicate whenthe tank 16 reaches a predetermined condition, e.g., 90% full, in orderto alert the operator. A further optional feature provides a differentaudible signal and/or emergency shut-off switch connected to the controlvalve 38 in the event of a failure of the processor 28 to operate as anelectronic measuring and/or mechanical control system for the loadingsystem 10.

Alternatively, the processor 28 can implement an automatic shut-offfunction, in which the valve 38 is automatically shut-off by theprocessor 28 when a shut-off condition occurs. In response to thetemperature data received from the junctions 18 of the probe 10, themicroprocessor 100 performs a temperature mismatch function using atemperature mismatch function calculator 110 to compare the temperaturesof the plurality of junctions 18 with each other and/or with a referencetemperature set by the operator through the input device 106.

A logic circuit 112 then determines from the compared temperatureswhether a predetermined shut-off condition exists. If so, the logiccircuit 112 sends a shut-off condition signal to the valve controlcircuit 114, which in turn sends a shut-off control signal to the valve38 via the transmission connection 42 to immediately shut-off the valve38 and so to stop the flow of molten sulfur 14 into the container 16.Alternatively, the valve control circuit 114 can be configured togradually slow and then stop the flow of molten sulfur 14 over apredetermined duration.

The logic circuit 112 can perform-one or more predetermined tests fordetermining whether a shut-off condition exists. In one embodiment, theshut-off condition exists when the temperature at a higher level in thecontainer 16 is higher than any temperature below that point. That is,with T_(i) being the i^(th) temperature measured by junction J_(i), thenthe shut-off condition exists if:T _(i) >T _(j) for some i>j, for all j=1, 2, . . . , i−1.

This condition indicates that sulfur solidification has occurred at thebottom layers of the sulfur 14, and so shutting off the valve 38 andstopping the flow of the sulfur 14 in order to avoid damaging the pumpsconnected to the source 40 of the molten sulfur 14.

Alternatively, the logic circuit 112 can simply test only the lowermostjunctions J₁, and J₃, such that if:T₃>T₂>T₁then the shut-off condition exists due to sulfur solidification at thelowermost layers of sulfur 14, and the valve 38 is shut off to avoiddamaging the pumps.

Alternatively or in addition, logic circuit 114 determines the shut-offcondition based on whether the temperature difference between the air inthe vapor space 32 and the molten sulfur 14 is greater than apredetermined set temperature. The set temperature can be calculated tobe the average temperature between the liquid and vapor phases.

For example, if SP equals the set point temperature, NT equals thenormal liquid sulfur temperature, VT equals the vapor space temperature,RH equals the real height of the surface of the molten sulfur 34 asmeasured above the distal or lower end 50 of, the probe 10, RHi equalsthe real height of the junction height measured above the distal orlower end 50, RC equals the real clearance or distance between thegenerally equidistantly spaced junctions 18, and RM equals the highlevel where the valve 38 has to shut down, then sulfur, NT is about 300°F. and VT is about 120° F., so SP is about 210° F.

The microprocessor 100 then performs the following calculations:SP=(NT+VT)/2,let INDEX=0,RH=RH1+RC*INDEX,

T₁>SP and RH<RM, then increment INDEX and repeat calculation of RH, but

if T₁≦SP or RH≧RM, then the shut off valve 38 is closed.

When the valve 38 is closed by this algorithm, the final value of RHdetermines the real height of the surface 34 of the molten sulfur 14relative to the distal tip 50 of the probe 10.

In all alternative embodiments, the processor 28 can function as atemperature controller 118 shown in FIG. 10 using an analog package andcomponents to process analog temperature sensing signals from thejunctions 18, such as thermocouples. As shown in FIG. 10, the analogtemperature sensing signals are input to an oscillator 120 to generateamplified temperature signals. An operator sets a reference temperatureusing a manual input device 122. The reference temperature sets theoutput of a reference oscillator 124 to generate a reference signal, anda multiplier 126 multiplies the temperature signals from thethermocouple junctions 18 with the reference signal. The multipliedsignal is applied to a low pass filter 128 to perform a temperaturemismatch function when an upper temperature point has a predetermineddifferential value or a higher value than any of the temperature valuesbelow that point, which can indicate sulfur solidification of the lowerportion of the sulfur 14 in the container 16.

In response to detecting such a temperature mismatch, the temperaturecontroller 118 generate an output signal from the low pass filter 128for transmission to the output stage 30. The output signal can include acontrol signal 130 which is transmitted to the shut off valve 38 totightly shut the valve 38, for example, to loading the sulfur 14 intothe container 16. In addition, the output signal can include thetemperatures at each junction 18 for display or recording.

The output stage 30 uses the output signal to control a display 116 todisplay a numerical value of the temperatures at different times duringthe loading operation, as well as the equivalent level 34 of sulfur 14in the container 16, and its equivalent capacity or weight in metrictons of sulfur depending on the geometry of the container 16. All of thedata required for the calculations can be input into the analog packagehaving the temperature controller 130 and the output stage 30.

For example, input device 106, such as a keypad, can be used to inputthe tank height, the junction or thermocouple heights, the minimum levelheight, the maximum or high level height which determines when to shutoff the valve 38, and any alarm settings. Thus, the invention is usefulto monitor the sulfur levels in addition to providing the automaticshut-off features.

The display 116 can also be activated to provide a warning light to beviewed by the operator of the system 12. The output signal can also betransmitted to an audio alarm device 132 to generate an audible warningto the operator.

FIG. 11 is a flowchart illustrating the operation of the invention, inwhich the probe 10 is inserted into the container 16 in step 134, andthe molten sulfur 14 begins to flow in step 136. As the molten sulfur 14fills the container 16, the processor 28 receives temperature signalsfrom the probe 10 in step 138, which are generated by the junctions 18contacting the molten sulfur 14 as the level 34 of molten sulfur 14rises.

The processor 28 then determines in step 140 the temperature values ateach respective junction 18, and the processor 28 determines if ashut-off condition has occurred in step 142. If not, the method loopsback to repeat steps 138-142 until a shut-off condition is detected instep 142. The processor 28 then generates a control signal which is sentto the valve 38 to automatically shut off the valve 38 in step 144.

By providing automatic monitoring and measurement of the level 34 of thesulfur 14 and automatic shut off of values 38 when loading sulfur 14into containers 16 such as tanks, the invention allows the operator tobe at a distance from the opening 26 of the container 16, as so theinvention eliminates the safety issues of exposing the operator tosulfur fumes, SO₂, and high H₂S levels.

As will be appreciated by one of ordinary skill in the art, the probe isdurable and resistant to damage due to ordinary inadvertent or carelesshandling during insertion, removal and storage by drivers or terminaloperation personnel. Know cables and chemical-resistant sockets can beprovided so that the processor, display and alarm devices can be locatedin an office or protective shelter away from contact with the moltensulfur or other product. As a separate component, the probe can beremoved for repair and maintenance, and a replacement installed on thefiller pipe.

Other modifications and features can be incorporated into the method andapparatus of the invention, the scope of which is to be determined bythe claims that follow.

The invention claimed is:
 1. A system for loading molten material into acontainer having an interior, said system comprising: a loading pipecoupled to a source of molten material, said loading pipe having anoutlet for discharging molten material into the interior of thecontainer through an overhead container opening; an elongated probemovable from a first position outside of the container into a secondposition in which at least a first portion of said probe is positionedvertically within the interior of the container; wherein said firstportion contains a plurality of vertically spaced temperature sensingdevices for producing electrical signals which vary as a function ofsensed temperature such that, as molten material is discharged into theinterior of the container through said loading pipe, said temperaturesensing devices at vertically increased heights come into thermalcontact with the molten material; a processor system located outside ofthe container and electrically coupled to said sensing devices forreceiving said electrical signals; wherein said processor system isprogrammed to calculating a value representing the current volume orlevel of molten material within the container based on physicalproperties of the container in combination with said electrical signals;and an external device coupled to the processor to provide an indicationto a user of the current volume or level of molten material within thecontainer; and further comprising an electrically controlled shutoffvalve for controlling the flow of molten material through said loadingpipe; wherein said processor system further includes programming meansfor monitoring said electrical signals and determining whether at leastone shutdown condition has occurred; and wherein said processor systemincludes programming means for closing said shutoff valve in response todetermining that a shutdown condition exists; wherein the processorsystem is programmed for loading molten sulfur into an insulatedcontainer such that a vapor zone forms over the molten sulfur.
 2. Thesystem of claim 1, wherein said external device is a visual display. 3.The system of claim 1, wherein each temperature sensing device iscoupled to the said processor system for providing output signalsrepresentative of sensed temperature of the respective sensing device;wherein said processor system is programmed to determine the existenceof a shutdown condition when the temperature of a temperature sensingdevice at a first vertical position is higher than the temperature of atleast one temperature sensing device at a second vertical position whichis lower than said first vertical position, indicating that sulfursolidification may have occurred.
 4. The system of claim 1, wherein thecontainer is part of a vehicle, and wherein the loading pipe isselectively moveable from a delivery position in which said outlet islocated in the interior of the container and a non-delivery position inwhich the outlet is located outside of the container.
 5. The system ofclaim 4, wherein said probe is mechanically coupled to said pipe formovement with said loading pipe such that, when said probe is in saidfirst position said loading pipe is in said non-delivery position, andsuch that, when said probe is in said second position said loading pipeis in said delivery position.
 6. The system of claim 1, wherein saidtemperature sensing devices comprise a lowermost sensing device, anuppermost sensing device, and a plurality of intermediate sensingdevices at vertical locations between said lowermost and uppermostsensing devices; wherein said lowermost sensing device is electricallycoupled to said processor system; wherein said uppermost sensing deviceis coupled to said processor system; wherein said lowermost, uppermost,and intermediate sensing devices are serially connected to one another;and wherein said processor system outputs an operating voltage to one ofsaid lowermost and uppermost sensing devices and receives output signalsfrom the other of said lowermost and uppermost sensing devices, andwherein said processor system determines a value of the current level orvolume based upon said output signals.
 7. A system for loading moltenmaterial into a container having an interior, said system comprising: aloading pipe coupled to a source of molten material, said loading pipehaving an outlet for discharging molten material into the interior ofthe container through an overhead container opening; an elongated probemovable from a first position outside of the container into a secondposition in which at least a first portion of said probe is positionedvertically within the interior of the container; wherein said firstportion contains a plurality of vertically spaced temperature sensingdevices for producing electrical signals which vary as a function ofsensed temperature such that, as molten material is discharged into theinterior of the container through said loading pipe, said temperaturesensing devices at vertically increased heights come into thermalcontact with the molten material; a processor system located outside ofthe container and electrically coupled to said sensing devices forreceiving said electrical signals; wherein said processor system isprogrammed to calculate a value representing the current volume or levelof molten material within the container based on physical properties ofthe container in combination with said electrical signals; and anexternal device coupled to the processor to provide an indication to auser of the current volume or level of molten material within thecontainer; and wherein the processor system is programmed for loadingmolten sulfur into an insulated container such that a vapor zone formsover the molten sulfur.